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As the post-COVID food industry grapples with a shrinking labor force and feeding a growing population, facility operators are turning to automation to improve efficiency, cut waste, and streamline production.
“With the rise in online delivery demand coupled with labor and space shortages in our market, we are seeing an increased demand for intelligent and space-saving automation,” says Mark Livesay, vice president of Automated Warehousing, Business Development Division,
ESI Group USA. “Dependence on automation is increasing at a rate that is difficult to comprehend. Traditional methods of manufacturing, storing, and assembling customer-specific orders simply cannot keep up with demand. The market is focused on providing more product options, to an increasing number of customers, delivered as soon as humanly (or automatedly) possible, at the lowest feasible cost.”
Choose Automation Wisely
There are many types of technologies and software currently on the market. Choosing among them should be driven by current operations and future goals, identifying weaknesses and opportunities in current operations, and understanding the gap between where you are today and where you need to be tomorrow. Automation types run the gamut from simple to elaborate. They include:
• Fixed automation is the simplest and most common, such as conveying systems that move units from one place to another for the entirety of its lifespan.
• Flexible automation are robots capable of switching from moving one type or size of goods to another.
• Integrated automation relies on process software, such as programmable logic controllers, to adjust production based on supply and demand data, minimizing overages and shortages.
• Collaborative robots adjust to spatial conditions to complete programmed tasks, such as picking a variety of products to complete an order.
Weighing the Benefits
No matter which type of automation you ultimately select, there are obvious benefits. For example, reduced complexity and difficulty of tasks, and increased performance. “Automation systems can increase productivity by any amount necessary to meet the business’ demands and goals,” says Livesay. “Consider that a simple automated storage and retrieval system (AS/RS) can double or triple order assembly.”
In addition to improving productivity, an AS/RS can double or triple the storage capacity of an existing facility to reduce reliance on additional storage facilities — ultimately eliminating costs to transport product between locations.
Automation is also making a positive impact on safety, enabling better monitoring and control throughout the processing chain. This is especially critical as food safety and cleanliness requirements are becoming more stringent.
Where Livesay sees automation making the most difference is in accurate and on-time order deliveries.
“Automation is online so that every article, movement, transaction or fault is recorded and accessible for traceability and analysis,” he says. “This visibility allows managers to analyze and enact effective change faster and helps avoid the reputational cost of poor performance and unreliable service.”
He adds, however, to weigh these benefits against the reality that automation places a high demand on energy to power its capabilities. “These two elements must be considered when installing automation,” he says. “Fortunately, emerging technologies are making automation more energy efficient.”
In addition to energy efficiency, automation is smarter, faster, and more streamlined to allow facility operators to achieve their current and future objectives. “Every plant and distribution center has unique conditions and goals that drive its path to a more efficient and productive future .”
Quick Facts
Food robotics market will jump from $2.47B in 2023 to $7.8B in 2033
70% of survey respondents rank productivity as the greatest benefit of automation
Upfront capital expense is the main barrier to automation implementation
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